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DOE OSTI2024

Development of prechamber enabled mixing-controlled combustion strategy for ultra-low methane emissions from lean burn natural gas engines

This numerical study explores the optimization of Prechamber Enabled Mixing-Controlled Combustion (PC-MCC) using natural gas in heavy-duty engines, aiming to enhance combustion efficiency to minimize methane slip and NOx emissions. The approach involves a prechamber ignition system, distinct from conventional spark ignition (SI) systems, to initiate combustion of direct injected natural gas. By leveraging the robust ignition characteristics of the prechamber, the PC-MCC method demonstrates significant potential in achieving efficient combustion akin to diesel engines but with lower greenhouse gas emissions. The research evaluates the effects of various geometric and operational parameters on the combustion process and emissions, including prechamber volume, nozzle diameter, direct injector (DI) geometry, and engine operating strategies. Computational Fluid Dynamics (CFD) simulations are utilized, focusing on a heavy-duty, single-cylinder engine modeled after the Caterpillar C9.3B engine. Key findings indicate that a prechamber volume of 3 cc, coupled with a nozzle diameter of 2.75 mm for two prechamber holes, strikes an optimal balance between combustion efficiency and emissions reduction. This configuration ensures robust combustion across a range of operating conditions while maintaining methane slip within targeted limits. Further investigation into DI geometry shows the significance of the injector umbrella angle and nozzle diameter in shaping the fuel-air mixing and combustion dynamics. An umbrella angle of 130° and a nozzle diameter of 300 microns are identified as optimal, promoting rapid and efficient combustion with minimized methane and NOx emissions. The study also investigates the impact of injection timing and pressure, highlighting their roles in controlling combustion timing and influencing emissions levels. Advanced injection timing is found to be crucial in achieving the desired low methane slip, whereas retarded injection timing assists to reduce NOx emissions while having a slight increase in methane emissions. Operating strategies incorporating various levels of Exhaust Gas Recirculation (EGR) are assessed for their effectiveness in further reducing emissions. The research demonstrates that a judicious combination of internal hot EGR and careful calibration of DI pressure and SOI timing can achieve significant reductions in NOx emissions while keeping methane slip under control. Specifically, an internal EGR level of 15%–25%, combined with DI pressures of 200–300 bar and injection timings at or after top dead center, is recommended. These findings contribute valuable insights into the development of advanced combustion techniques for natural gas engines, offering a viable pathway to reduce methane slip without compromising engine efficiency or performance. The PC-MCC system presents a promising solution for the future of heavy-duty natural gas engine technology to reduce methane emissions.

Nsaif, Osama↗

DOE OSTI2018

Gasoline Engine and Fuels Offering Reduced fuel Consumption and Emissions (GEFORCE)

The GEFORCE project resulted from a collaborative proposal submitted to a U.S. DOE funding opportunity announcement. The CRADA reported herein was put in place to support the GEFORCE project. The project objective was to establish key engine technologies and fuel characteristics that enable very high fuel efficiency with very low emissions in future vehicles. A matrix of study fuels was designed and produced to support engine experiments in an advanced engine. The advanced engine was constructed and prepared for operation in an engine test cell at a 3rd party laboratory. ORNL conducted engine experiments using a 2.0 LTG engine and used the resulting data to estimatefuel economy values for a mid-size sedan using a vehicle model established in Autonomie. The projected fuel economy trends versus driving schedule were consistent with those identified in a previous projectconducted in partnership with the Coordinating Research Council (CRC), AVFL-20. Additional vehicle modeling is anticipated when data are available from the advanced engine.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Fuel Effects on Multimode Engine Operation (Sandia National Laboratories) (DOE VTO Annual Progress Report for FY21)

In total, light-duty vehicles in the United States travel on the order of 3 trillion miles annually, providing tremendous societal and personal benefits. However, the environmental burden is excessive, prompting Co-Optimization of Fuel and Engines (Co-Optima) program efforts to provide the science needed to increase engine efficiency and produce non-fossil fuels with reduced greenhouse gas emissions. Boosted spark-ignition (SI) engines provide high power density by offering high loads and engine speeds, making them light-weight and attractive for light-duty vehicles. Unfortunately, the engine efficiency drops off at lower loads and speeds, where the engine spends most time during typical driving. Multimode SI engines can use a more efficient advanced lean combustion mode at lower loads and speeds, while reverting to boosted SI under high-load conditions. Within Co-Optima, multiple advanced lean combustion modes have been explored; these include stratified-charge SI, pre-chamber lean SI, and advanced compression ignition (ACI) techniques such as spark-assisted compression ignition (SACI). For these combustion modes, focus has been on determining fuel properties that enable higher engine efficiency, clean and stable combustion, and effective exhaust aftertreatment. This report highlights recent efforts funded by the Vehicle Technologies Office at multiple National Laboratories that supported the multimode project in Co-Optima. It also includes a brief summary of biofuel production research funded by the Bioenergy Technologies Office.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Oxygenated Fuel Blending Effects in a Mixing-Controlled Compression-Ignition Engine Equipped with Ducted Fuel Injection [Slides]

Continued creation of harmful emissions such as NO x and soot from compression-ignition engines utilizing mixing-controlled combustion systems (i.e., diesel engines) remains a problem and is the subject of on-going research. The inherently high efficiency, relatively low cost, and numerous other desirable attributes of such engines, coupled with a widely supported infrastructure, motivates their continued advancement. Recently, a scientifically distinct and mechanically simple technology called ducted fuel injection (DFI) has shown a robust ability to allow such engines to operate with simultaneously low engine-out soot and NO x emissions when it is employed with simulated exhaust-gas recirculation. To better understand the property ranges of sustainable, oxygenated-fuel blending stocks that will most improve engine performance, two oxygenated blendstocks were separately blended with a commercial diesel base fuel and tested within a heavy-duty diesel optical engine equipped with a four-duct DFI configuration. Conventional and crank-angle-resolved optical diagnostics were used to elucidate the effects of fuel ignition quality, oxygenate molecular structure, and overall oxygen content on engine performance.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Improving Efficiency of Off-Road Vehicles by Novel Integration of Electric Machines and Advanced Combustion Engines

Modern off-road equipment will increasingly rely on electrified implements that will deliver precision control with a smaller footprint than hydraulics. The primary energy converter, however, will be an onboard reciprocating internal combustion engine because of the power density of hydrocarbon fuels in comparison to electrical energy storage and the remote locations where much of this equipment is deployed. Adding energy storage and electric machines creates opportunities to improve efficiency while reducing emissions. This program investigated approaches to take advantage of the extra flexibility that an enhanced electrical system to enable high-efficiency, low-emissions combustion technologies. The current program evaluated hybridization of both the torque application and air-handling systems to maximize efficiency while minimizing cost. This program designed, analyzed and tested a hybrid off-road vehicle consisting of a series electric powertrain with energy storage, an electrified air system, and a 33% downsized diesel engine. Detailed comparisons were made between the base powertrain and the developed powertrain using powertrain simulations, engine testing, and vehicle testing. The key results of the study are: • The resulting vehicle reduces fuel consumption by 5% to 15% at equal productivity. The primary improvements were due to recovery of regenerative braking losses for cycles where large transients are encountered. • The electrified air system was an enabler to allow engine downsizing. This was most important for duty-cycles where the engine primarily operated at moderate loads and had few low speed high torque conditions. • Engine level improvements showed re-optimization of the powertrain is possible when electrified air handing is available. Increased exhaust gas recirculation and advanced injection timing allowed up to a 15% reduction in brake specific fuel consumption at equal NOx and transient response. Compared to the larger engine, the downsized engine achieves up to an 18% reduction in brake specific fuel consumption over the non-road transient cycle. • The life cycle analysis and total cost of ownership study showed that the hybrid powertrain has the potential to reduce 5-year CO2 and total cost of ownership by ~6% over the baseline vehicle. The results also indicated that a pure battery electric vehicle is not feasible in this application and is likely to increase the CO2 emissions due to the CO2 from battery production. A hybrid powertrain with low carbon fuels shows the potential to substantially reduce CO2 and total cost of ownership.

02 PETROLEUM↗

DOE OSTI2024

Rapid Design and Engineering of Smart and Secure Microbiological Systems (Final Report)

The design and application of successfully engineered biosystems requires an understanding of how engineered microbes will interact with other organisms – either as one-on-one competitors or in the context of microbial consortia. Engineering microorganisms from first principles for non-laboratory, environmental applications is inherently challenging because: (1) engineered systems tend to quickly revert back to their wild-type behaviors; and (2) these systems typically pay a price in reduced fitness, making them uncompetitive against invasive contaminating species (i.e., metabolic burden). For this project, we used a synthetic biology-based strategy to investigate the organization, control, stabilization, and destabilization of natural and engineered microbes. This approach enabled development of (1) single-strain systems capable of detecting and responding to target organisms in the environment; (2) a pipeline for refining and engineering biological constructs in new, non-model host organisms; and (3) improved systems for rapidly designing, engineering, and assaying new biological modules. This coupled approach to safeguard system design is predictable and portable across bacterial species and is focused on microbes that are part of the beneficial plant microbiome. A long-term goal beyond the proposed research is to enable the rational engineering of microbial communities based on first principles of biological design that mimic the smart performance of microorganisms observed in natural systems.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2018

Solid Particle Number and Mass Emissions from Lean and Stoichiometric Gasoline Direct Injection Engine Operation

In this work, engine-out particle mass (PM) and particle number (PN) emissions were experimentally examined from a gasoline direct injection (GDI) engine operating in two lean combustion modes and one stoichiometric mode with a fuel of known properties. Ten steady state operating points, two constant speed load steps, and an engine cold start were examined. Results showed that solid particles emitted from the engine under steady state stoichiometric conditions had a uniquely broad size distribution that was relatively flat between the diameters of 10 and 100 nm. In most operating conditions, lean homogenous modes can achieve lower particle emissions than stoichiometric modes while improving engine thermal efficiency. Alternatively, lean stratified operating modes resulted in significantly higher PN and PM emissions than both lean homogeneous and stoichiometric modes with increased efficiency only at low engine load. Stoichiometric load steps showed minimal soot emissions while ash-mode emissions spike dramatically due to oil consumption caused by piston ring adjustment. Correlation of PN to PM for steady state stoichiometric cases was in good agreement with that reported from multiple prior studies for both diesel and stoichiometric GDI engines. However, the lean cases resulted in higher PN to PM ratios indicating more small particles per unit mass. High ash particle concentration, especially in lean operation illustrates that oil control is important for mitigating impacts on downstream gasoline particulate filters (GPF) from which ash particles are cannot be removed during filter regeneration. Further research is necessary to elucidate the origin and composition of sub-23 nm particles from GDI engines and their effect on aftertreatment technology if lean homogeneous modes are to be employed.

Bock, Noah↗

DOE OSTI2018

Development and validation of a three pressure analysis (TPA) GT-Power model of the CFR F1/F2 engine for estimating cylinder conditions

The CFR engine is the widely accepted platform to test standard Research Octane Number (RON) and Motored Octane Number (MON) for determining anti-knock characteristics of motor fuels. With increasing interest in engine downsizing, up-torquing, and alternative fuels for modern spark ignition (SI) engines, there is a need to better understand the conditions that fuels are subjected to in the CFR engine during octane rating. To take into account fuel properties, such as fuel heat of vaporization, laminar flame speed and auto-ignition chemistry; and understand their impacts on combustion knock, it is essential to estimate accurate cylinder conditions. In this study, the CFR F1/F2 engine was modeled using GT-Power with the Three Pressure Analysis (TPA) and the model was validated for different fuels and engine conditions. The finite element cylinder model was applied to better estimate heat transfer and cylinder wall temperatures of the cast iron combustion chamber (piston, cylinder, and head) of the CFR engine under continuous standard knocking operation. Uncertainty of unburned gas temperature and cylinder wall temperatures estimation was analyzed depending on uncertainty in experimentally measured and prescribed model input parameters. The model was finally used to estimate the IVC conditions (trapped mass, residual gas fraction, and temperature), as well as unburned gas temperature and cylinder wall temperatures for various fuels throughout the engine cycle.

Choi, Seungmok↗

NASA NTRS1956

Effect of Engine Operating Variables on Combustor-inlet Parameters

Studies of the fundamental processes of combustion are usually concerned with wide ranges of investigation of individual processes. In general, each fundamental combustion process may be studied in an environment that is most suited to its evaluation and possibly unrelated basically to any practical application. The majority of the data presented in volume I of this series concern the fundamental aspects of combustion as functions of the individual occurrence of various contributing processes. In a jet engine, however, the various fundamental combustion processes may occur simultaneously and may interact. Furthermore, the engine environment usually does not permit independent variation of single combustion parameters, since specified operating conditions impose specific values on the parameters. In volume II, data are presented to show the effect of operating conditions on the over-all combustion process in different combustion components. To show the effect of operating conditions, it is necessary to specify the range of these conditions within which combustion components may operate. Therefore, this chapter presents only the operating conditions that might be required in the primary combustors and afterburners of typical current turbojet engines. (Corresponding information on ram-jet engines is presented in ch. xisi.) This chapter is not intended to serve as an explanation of engine operation. The operating conditions of the combustion components are presented in terms of total pressures and temperatures at the primary-combustor and afterburner inlets, reference velocities and outlet total temperatures of the primary combustors, and velocities at the plane of the flameholder in the afterburners. The data are presented to relate the operating regions of typical current turbojet combustion components to flight altitudes, Mach numbers, and modes of engine operation. Specifically, data are presented for the combustion parameters of the primary combustor and afterburner of three turbojet engines having rated compressor total-pressure ratios of 5, 8, and 12 under full-throttle conditions. Operational data for the primary combustor also include part-throttle operation at 70, 80, and 90 percent of rated engine speed and windmifling operation. The range of flight conditions includes altitudes from sea level to 65,000 feet and flight Mach numbers from zero to 1.6.

Jones, A. W.↗

NASA NTRS1973

Control of turbofan lift engines for VTOL aircraft

The use of turbofan engines as lift units for VTOL aircraft poses new engine control problems. At low flight speeds, the lift units must provide the fast thrust response needed for aircraft attitude and height control. The results are presented of an analytical study of the dynamics and control of turbofan lift engines, and methods are proposed for meeting the response requirements imposed by the VTOL aircraft application. Two types of lift fan engines are discussed: the integral and remote. The integral engine is a conventional two-spool, high bypass ratio turbofan designed for low noise and short length. The remote engine employs a gas generator and a lift fan which are separated by a duct, and which need not be coaxial. For the integral engine, a control system design is presented which satisfies the VTOL response requirements. For the remote engine, two unconventional methods of control involving flow transfer between lift units are discussed. Both methods are shown to have thrust response near the required levels.

Sellers, J. F.↗

NASA NTRS1973

A simulator investigation of the influence of engine response characteristics on the approach and landing for an externally blown flap aircraft. Part 1: Description of the simulation and discussion of results

Investigation of the influence of engine response characteristics on approach and landing operations of a powered lift aircraft were carried out in a piloted ground-based simulator. The aircraft simulated was a four engine, externally-blown jet-flap configuration having an 80 pound wing loading and .56 thrust to weight ratio. Results indicate that for ideal operating conditions and minimal pilot reaction delay, substantial reductions in engine-out wave-off altitude increment and touchdown sink rate for engine-out landings can be achieved with the fast engine compared to the slow engine response. However, delays in pilot reaction of one to two seconds diminish the advantage of rapid thrust response. A need exists for some form of automatic cueing of the pilot or automatic engine control to enable the potential of rapid thrust response to be realized in improving safety in the event of an engine failure.

Franklin, J. A.↗

NASA NTRS1972

The Viking Orbiter 1975 beryllium INTEREGEN rocket engine assembly.

Description of the conversion of the Mariner 9 rocket engine for Viking Orbiter use. Engine conversion consists of replacing the 40:1 expansion area ratio nozzle with a 60:1 nozzle of the internal regeneratively (INTEREGEN) cooled rocket engine. Five converted engines using nitrogen tetroxide and monomethylhydrazine demonstrated thermal stability during the nominal 2730-sec burn, but experienced difficulty at operating extremes. The thermal stability characteristic was treated in two ways. The first treatment consisted of mapping the operating regime of the engine to determine its safest operating boundaries as regards thermal equilibrium. Six engines were used for this purpose. Two of the six engines were then modified to effect the second approach - i.e., extend the operating regime. The engines were modified by permitting fuel injection into the acoustic cavity.

Martinez, R. S.↗

NASA NTRS1974

NASA/GE quiet engine C acoustic test results

The acoustic investigation and evaluation of the C propulsion turbofan engine are discussed. The engine was built as a part of the Quiet Engine Program. The objectives of the program are as follows: (1) to determine the noise levels produced turbofan bypass engines, (2) to demonstrate the technology and innovations which will reduce the production and radiation of noise in turbofan engines, and (3) to acquire experimental acoustic and aerodynamic data for high bypass turbofan engines to provide a better understanding of noise production mechanisms. The goals of the program called for a turbofan engine 15 to 20 PNdB quieter than currently available engines in the same thrust class.

Kazin, S. B.↗

NASA NTRS1974

Study of the costs and benefits of composite materials in advanced turbofan engines

Composite component designs were developed for a number of applicable engine parts and functions. The cost and weight of each detail component was determined and its effect on the total engine cost to the aircraft manufacturer was ascertained. The economic benefits of engine or nacelle composite or eutectic turbine alloy substitutions was then calculated. Two time periods of engine certification were considered for this investigation, namely 1979 and 1985. Two methods of applying composites to these engines were employed. The first method just considered replacing an existing metal part with a composite part with no other change to the engine. The other method involved major engine redesign so that more efficient composite designs could be employed. Utilization of polymeric composites wherever payoffs were available indicated that a total improvement in Direct Operating Cost (DOC) of 2.82 to 4.64 percent, depending on the engine considered, could be attained. In addition, the percent fuel saving ranged from 1.91 to 3.53 percent. The advantages of using advanced materials in the turbine are more difficult to quantify but could go as high as an improvement in DOC of 2.33 percent and a fuel savings of 2.62 percent. Typically, based on a fleet of one hundred aircraft, a percent savings in DOC represents a savings of four million dollars per year and a percent of fuel savings equals 23,000 cu m (7,000,000 gallons) per year.

Steinhagen, C. A.↗

NASA NTRS1976

Preliminary Evaluation of a Turbine/Rotary Combustion Compound Engine for a Subsonic Transport

The fuel consumption of a modern compound engine with that of an advanced high pressure ratio turbofan was compared. The compound engine was derived from a turbofan engine by replacing the combustor with a rotary combustion (RC) engine. A number of boost pressure ratios and compression ratios were examined. Cooling of the RC engine was accomplished by heat exchanging to the fan duct. Performance was estimated with an Otto-cycle for two levels of energy lost to cooling. The effects of added complexity on cost and maintainability were not examined and the comparison was solely in terms of cruise performance and weight. Assuming a 25 percent Otto-cycle cooling loss (representative of current experience), the best compound engine gave a 1.2 percent improvement in cruise. Engine weight increased by 23 percent. For a 10 percent Otto-cycle cooling loss (representing advanced insulation/high temperature materials technology), a compound engine with a boost PR of 10 and a compression ratio of 10 gave an 8.1 percent lower cruise than the reference turbofan.

Civinskas, K. C.↗

NASA NTRS1978

Stirling engine design manual

This manual is intended to serve both as an introduction to Stirling engine analysis methods and as a key to the open literature on Stirling engines. Over 800 references are listed and these are cross referenced by date of publication, author and subject. Engine analysis is treated starting from elementary principles and working through cycles analysis. Analysis methodologies are classified as first, second or third order depending upon degree of complexity and probable application; first order for preliminary engine studies, second order for performance prediction and engine optimization, and third order for detailed hardware evaluation and engine research. A few comparisons between theory and experiment are made. A second order design procedure is documented step by step with calculation sheets and a worked out example to follow. Current high power engines are briefly described and a directory of companies and individuals who are active in Stirling engine development is included. Much remains to be done. Some of the more complicated and potentially very useful design procedures are now only referred to. Future support will enable a more thorough job of comparing all available design procedures against experimental data which should soon be available.

Martini, W. R.↗

NASA NTRS1978

Orbit Transfer Vehicle (OTV) engine phase A study

Requirements for the orbit transfer vehicle engine were examined. Engine performance/weight sensitivities, the effect of a service life of 300 start/shutdown cycles between overalls on the maximum engine operating pressure, and the sensitivity of the engine design point (i.e., thrust chamber pressure and nozzle area ratio) to the performance requirements specified are among the factors studied. Preliminary engine systems analyses were conducted on the stage combustion, expander, and gas generator engine cycles. Hydrogen and oxygen pump discharge pressure requirements are shown for various engine cycles. Performance of the engine cycles is compared.

Mellish, J. A.↗

NASA NTRS1979

New opportunities for future small civil turbine engines: Overviewing the GATE studies

An overview of four independent studies forecasts the potential impact of advanced technology turbine engines in the post 1988 market, identifies important aircraft and missions, desirable engine sizes, engine performance, and cost goals. Parametric evaluations of various engine cycles, configurations, design features, and advanced technology elements defined baseline conceptual engines for each of the important missions identified by the market analysis. Both fixed-wing and helicopter aircraft, and turboshaft, turboprop, and turbofan engines were considered. Sizable performance gains (e.g., 20% SFC decrease), and large engine cost reductions of sufficient magnitude are predicted to challenge the reciprocating engine in the 300-500 SHP class.

Strack, W. C.↗